Method for making foot supports



arch 14, 1967 E. J. WEGLEY 3,309,447

METHOD FOR MAKING FOOT SUPPORTS Filed Feb. 17, 1964 2 Sheets-Sheet 1 INVENTOR.

EARLE J WEGLEY ATTORIVE Y5 March 14, 1967 E. J. WEGLEY 3,309,447

METHOD FOR MAKING FOOT SUPPORTS Filed Feb. 17, 1964 2 Sheets-Sheet z INVENTOR.

T1619 E E J WEGLEY jM/% MJ AT To/ e/vEYs United States Patent 3,309,447 METHOD FOR MAKING FOOT SUPPORTS Earle J. Wegley, Minneapolis, Minn., assignor of onehalf to James E. Wegley, Golden Valley, Minn. Filed Feb. 17, 1964, Ser. No. 345,185 3 Claims. (Cl. 264-223) This invention relates generally to a novel method for the formation of supports for body extremities, and more particularly it relates to a method for making foot supports.

An important object of the present invention is a provision of a convenient method for the formation of a foot support which accurately conforms to the surface contours of the foot.

Another object of the present invention is the provision of a method of taking the impression of a persons foot by using a pair of flexible bags filled with a plastic hardenable material and disposed on a supporting surface in generally flat face-to-face relation with one of the bags on top of the other and with the impression being taken in the upper bag.

It 'is noted that when taking the impression of a persons foot preparatory to the making of a support therefor, varying degrees of foot pressure applied by the person upon the molding element will produce varying contours in the mold. With this in mind, the present method and apparatus is particularly useful in the taking of an accurate impression of the persons foot, even when a relatively great pressure is applied by a person to the molding element, such as for example a pressure applied equal to that used when walking. More particularly, the present invention utilizes a pair of generally flat flexible bags filled with a plastic hardenable material and placed in generally fiat face-to-face relation on a supporting surface and with one of the bags on top of the other, whereby the impression is taken in the upper bag with the lower bag acting as a cushion for and being deformed generally with the impressed upper bag. In this manner, a generally even cushion is provided for the impression so as to prevent untrue or uneven reproductions.

A further object of the present invention is the provision of a method utilizing a molding element comprising a bag having generally similar and spaced apart walls formed from a flexibe cloth material and having their perimetric portions disposed adjacent one another, with stitch means securing together the perimetric portions of the walls, and further comprising a plastic hardenable material filling the interior of the bag.

Still further objects of the present invention reside in the provision of a novel method of taking the impression of a persons body extremity which is quick, simple and accurate in its quality of impression; and which may be adapted for use in the preparation of a socket or support for a stump resulting from leg amputations and the like, particularly when the persons weight or bearing load is an important factor so that the accurateness and quality of the impression taken is an important consideration.

The above and still further objects and advantages of the present invention will become apparent from a consideration of the following specification, attached claims and appended drawings.

Referring to the drawings, wherein like reference characters indicate like parts or elements throughout the several views:

FIG. 1 is a view in top plan showing the upper bag of a pair of bags utilized in this invention, and showing the same before the first step of the method of this invention:

FIG. 2 is a view in section taken on the line 22 of FIG. 1;

FIG. 3 is a view in section corresponding generally to v we FIG. 2 but showing a second step of the method wherein the person's foot (dotted lines) has been impressed into the upper bag;

FIG. 4 is a view in transverse section taken on the line 4-4 of FIG. 3;

FIG. 5 is a view in perspective of a third bag utilized in a further step of the method of this invention;

FIG. 6 is a view in section showing a further step of the present invention;

FIG. 7 is a view in elevation showing further steps in the practice of the method of the present invention;

FIG. 8 is a view in perspective of a foot support provided according to the method of the present invention;

FIG. 9 is a view in section of the foot support shown in FIG. 8, with the persons foot and shoe being shown in dotted lines.

Referring to the drawings, and particularly FIGS. 1 and 2 thereof, a pair of molding elements or bags are provided in accordance with the present invention. The lower bag is represented generally by the reference numeral 1, and the upper bag is represented by the reference numeral 2. The upper bag 2 comprises upper and lower generally similar and spaced apart walls 3, 4, respectively. The perimetric portion 5 of the upper wall 3 is secured, as by stitching or the like, to the perimetric portion 6 of the lower wall 4. The lower bag 1 is constructed in a similar manner with the perimetric portion 7 of the upper wall 8 thereof secured, as by stitching or the like, to the corresponding perimetric portion 9 of the generally similar lower Wall 10. The bags 1, 2 are preferably formed from a flexible cloth material, although other suitable materials may be substituted. Prior to the complete closing of the bags 1, 2, the same are filled with a plastic hardenable material 11, such as for example a molding plaster or the like made from gypsum. Preferably, and as shown in FIG. 2, the upper bag 2 is slightly smaller in thickness or transverse dimension than is the bottom or lower bag 1.

Referring now to the method of the present invention disclosed herein, the first step is to place the pair of flexible bags 1, 2 filled with the material 11 in generally flat face- -to-face relation on a supporting surface 12, in the manner illustrated in FIG. 2. Of course, it will be understood that the bags 1, 2 have previously been soaked in water or other wetting agent so as to place the bags 1, 2 in a plastic or moldable condition. It is preferable to prepare the. bags 1, 2 so that the plaster material 11 will be of a relatively thin consistency therein.

Referring to the next step of the present invention illustrated in FIG. 3, the person places his foot upon the upper wall 3 of the upper bag 2 and exerts bodily weight or pressure upon the bags 1, 2. It will be understood that varying degrees of foot pressure produce varying contours of the bottom portion of the foot. However, it has been determined that it is preferable for the person to apply the pressure, by use of his bodily weight, to the bags 1, 2 corresponding to the pressure most often applied normally by the person, such as for example when walking. In this manner, an impression is taken of the bottom portion of a persons foot in the upper bag 2 to form a female mold, represented by the reference numeral 13 in FIGS. 3-6. The lower bag 1 acts as a cushion for and is deformed generally with the impressed upper bag 2, as illustrated particularly in FIGS. 3 and 4 of the drawing. This is a very important featureof the present invention since it provides a true and accurate impression of the bottom of the persons foot. In this connection, it will be noted in the illustration of FIGS. 3 and 4 that the cushioning provided by the lower 'bag 1 has prevented the upper and lower walls 3, 4 of the upper bag from meeting one another.

After the impression has been made to form the female hold 13, as illustrated in FIG. 3, the persons foot is emoved and the bags 1, 2 are cured, such as for example )y merely permitting the molding plaster 11 to set or zarden.

Referring to FIG. 5, a third bag '14 formed from a lexible material, such as cloth, in a manner similar to he bags 1, 2 is shown therein. The third bag 14 is also illed with the plastic hardenable material 11 in a manner imilar to the construction of the bags 1, 2. This third vag 14, which is somewhat smaller than the pair of bags 2, is soaked or otherwise treated to place the same in L plastic condition, and then the third bag 14 is inserted vithin the cured female mold 13, as illustrated in FIG. 6. fhe bag is then pressed into the impresion of the female nold 13 to form a male mold, represented generally by he reference numeral 15 in FIGS. 6 and 7. The male nold 15 is then cured or permitted to harden and thererfter removed from the female mold 13.

As illustrated in FIGS. 7 and 8, the next step of the nethod disclosed herein is to transfer the impression or :onfiguration of the male mold 15 to form a foot support )f a relatively thin rigid material, such as for example a hermoplastic resin material. As shown by dotted lines n FIG. 7, this may be done by placing a sheet of the hermoplastic material over the desired surface or contour )f the male mold 15, after which heat may be applied hereto to form or bend the sheet material to conform o the configuration of the desired portion of the male nold 15. In this manner, the foot support, shown by iull lines in FIGS. 7-8, may be formed. FIG. 9 illusrates a placement of the foot support 16 Within a shoe vith the persons foot bearing thereagainst.

It willbe appreciated that the novel method disclosed rerein is useful for the making of supports for other body :xtremities, and the above disclosure with respect to the naking of a foot support is intended to be only illusrative of the principles of the present invention. For nstance, it will be appreciated that the present invention s useful in preparing sockets or supporting elements for he stumpvof a persons leg resulting from an amputation )r the like, particularly where weight bearing is a factor.

This invention has been tested and found to be com- )letely satisfactory for the performance of the above obects and advantages; and while preferred embodiments )f the present invention have been disclosed above, it will )e understood that the same may be modified without leparture from the scope and spirit of the appended :laims.

What is claimed is:

l. A method of making a foot support, said method :omprising:

(a) placing a pair of generally flat flexible bags filled with a plastic hardenable material in generally flat face-to-face relation with one of said bags on top of the other,

(b) taking the impression of the bottom portion of a persons foot in the upper bag to form a female mold with the lower bag acting as a cushion for and being deformed generally with the impressed upper s (c) transferring the impression of said female mold to a foot support of thin. generally rigid material formed to the configuration of said female mold.

2-. A method of making a foot support, said method comprising:

(a) placing a pair of generally flat flexible bags filled with a plastic hardenable material in generally flat face-to-face relation with one of said bags on top of the other,

(b) taking the impression of the bottom portion of a persons foot in the upper bag to form a female mold with the lower bag acting as a cushion for and being deformed generally with the impressed upper bag,

(c) curing the female mold formed by said pair of bags, and

(d) transferring the impression of said female mold to a foot support of thin generally rigid material formed to the configuration of said female mold.

3. A method of making a foot support, said method comprising: i

(a) placing a pair of generally fiat flexible bags filled with a plastic hardenable material in generally flat face-to-face relation on a supporting surface with one of said bags on top of the other,

(b) taking the impression of the bottom portion of a persons foot in the upper bag to form a female mold with the lower bag acting as a cushion for and being deformed generally with the impressed pp b (c) curing the female mold formed by said pair of bags,

((1) inserting a third bag filled with a plastic hardenable material within the cured female mold to form a male mold corresponding to the impression of said female mold,

(e) curing said male mold, and

(f) transferring the impression of said male mold to a foot support of thermoplastic sheet material formed to the configuration of said male mold.

References Cited by the Examiner B. SNYDER, Assistant Examiner, 

1. A METHOD OF MAKING A FOOT SUPPORT, SAID METHOD COMPRISING: (A) PLACING A PAIR OF GENERALLY FLAT FLEXIBLE BAGS FILLED WITH A PLASTIC HARDENABLE MATERIAL IN GENERALLY FLAT FACE-TO-FACE RELATION WITH ONE OF SAID BAGS ON TOP OF THE OTHER, (B) TAKING THE IMPRESSION OF THE BOTTON PORTION OF A PERSON''S FOOT IN THE UPPER BAG TO FORM A FEMALE MOLD WITH THE LOWER BAG ACTING AS A CUSHION FOR AND BEING DEFORMED GENERALLY WITH THE IMPRESSED UPPER BAG, (C) TRANSFERRING THE IMPRESSION OF SAID FEMALE MOLD TO A FOOT SUPPORT OF THIN GENERALLY RIGID MATERIAL FORMED TO THE CONFIGURATION OF SAID FEMALE MOLD. 